COMMON RAIL (for DPF) REMOVAL

Note


  • When replacing the injectors (including shuffling the injectors between the cylinders), common rail or cylinder head, it is necessary to replace the injection pipes with new ones.

  • When replacing the fuel supply pump, common rail, cylinder block, cylinder head, cylinder head gasket or timing gear case, it is necessary to replace the fuel inlet pipe with a new one.

  • After removing the injection pipes and fuel inlet pipe, clean them with a brush and compressed air.


  1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.

  2. REMOVE ELECTRIC EGR CONTROL VALVE ASSEMBLY WITH NO. 2 EGR VALVE AND EGR COOLER

    Click here

  3. REMOVE NO. 4 INJECTION PIPE SUB-ASSEMBLY


    1. A01DW4L

      Remove the bolt, nut and 2 No. 2 injection pipe clamps.

    2. A01E26N

      Using a 17 mm union nut wrench, loosen the union nuts and remove the No. 4 injection pipe.

  4. REMOVE WIRING HARNESS CLAMP BRACKET


    1. A01DV6CE01
      Text in Illustration
      *A for LHD
      *B for RHD
      *1 Wiring Harness Clamp Bracket

      Detach the wire harness clamp.

    2. Remove the bolt and wiring harness clamp bracket.

  5. REMOVE NO. 2 FUEL PIPE


    1. A01DZ44

      Disconnect the vacuum switching valve connector and 2 vacuum transmitting hoses.

    2. A01DWSC

      Using a 6 mm hexagon wrench, remove the supply pump hollow screw and gasket.

      Text in Illustration
      A01E2TX Bolt
      A01DZ8Z Supply Pump Hollow Screw
      A01E01H Fuel Check Valve
      A01DXHC Union Bolt

    3. Remove the fuel check valve, union bolt and 2 gaskets.

    4. Remove the 3 bolts and No. 2 fuel pipe.

  6. REMOVE NO. 3 NOZZLE LEAKAGE PIPE


    1. A01DZSF

      Disconnect the 3 fuel hoses.

      Text in Illustration
      A01DZ8Z Fuel Check Valve

    2. Remove the 2 bolts.

    3. Remove the fuel check valve, gasket and No. 3 nozzle leakage pipe.

  7. REMOVE NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY


    1. A01E159

      Remove the 2 bolts.

      Text in Illustration
      A01DZ8Z Union Bolt

    2. Remove the union bolt, gasket and No. 2 nozzle leakage pipe.

  8. REMOVE OIL FILTER SUB-ASSEMBLY


    1. A01DYHFE01

      Using SST, remove the oil filter.

      SST
      09228-07501

      Tech Tips

      Insert the drain hose in the oil filter. Put the disposal container beneath the drain hose to collect the oil from the oil filter.

  9. REMOVE COMMON RAIL ASSEMBLY


    1. Disconnect the pressure discharge valve connector.

    2. A01DVPB

      Remove the 2 bolts and common rail.

      Note

      Do not remove the pressure discharge valve or fuel pressure sensor.